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Application of human-machine interface in liquid filling machines
2022.09.24

Summary:The liquid filling machine determines the measurement accuracy through the unit time flow rate, monitors the operating status through the human-machine interface touch screen, can modify the operating parameters online, and exchanges data with the server for various data collection and processing to achieve data sharing.

Liquid filling machine is mainly composed of weighing platform, supporting column, ball screw, filling pipe, filling gun, pot pressure, moving filter, ventilation device, electrical control box, stepping motor and so on. The weighing instrument support column supports the whole filling mechanism, including the rack of ball screw, stepping motor, filling pipe and so on. The stepping motor drives the ball screw to drive the filling pipe and filling gun to raise and lower. When filling, the material is pressed into the packing iron drum through the movable filter, filling pipe and filling gun. Before filling, the gun is usually lowered to a position closer to the bottom of the barrel, so that the gun nozzle is always above the average liquid level of the material during the whole filling process, which can effectively ensure that the material can be completely filled into the packaging barrel and keep the density of the material in different positions in the packaging barrel consistent. After filling, the spray gun should be lifted automatically and slowly with the increase of filling weight, and the ball screw is driven by the stepping system to lift the spray gun.

The automatic filling machine adopts programmable logic controller to comprehensively monitor the operation status of related equipment to improve the safety operation coefficient and collect and process all kinds of data to exchange data with the server in order to realize the sharing of data. Monitoring management is through the computer technology network technology database management system and software technology, filling data and monitoring information centralized processing, so that its daily work such as sending and receiving, transfer and other operational procedures, standardization, institutionalization of each step of the operation of the law can be relied upon to have the basis for checking the management loopholes to be eliminated. Daily data reporting, auditing and summarizing timely and accurate filling information. With alarm display, alarm management and event query, printing: real-time data collection, archiving, management and trend graph display; production statistics report generation and printing, the realization of the filling before the site contact and operation mode (linkage / single-action) to choose the function: the realization of the filling over the kind of automatic switching and sequential starting and stopping of the equipment: including the realization of the manual control of the local control and remote control of the mutual switching; Alarm Screen Display; print alarms, reports, events; real-time alarm/event information printing function: event logging (operator operation records process parameters or equipment status and control mode change alarm generation, confirmation, etc.) with a variety of alarm monitoring, such as: liquid level high/low limit and other alarms with the configuration of parameter modification of the automatic recording and all types of alarms automatically record the function of the system to improve the traceability of the system to enhance the preventive capability of the system Monitoring system hardware troubleshooting and status monitoring function, historical data collection and automatic archiving and storage function: with a variety of categories of data query function.

The automatic filling machine calculates the pulse signal of pipeline tube flow through the weighing module, obtains the actual weight of liquid discharged by the weighing system, and controls the motor operation according to the difference between the actual filling volume and the set value, so as to realize precise control of the filling volume according to the actual needs. Automatic filling machine is mainly composed of DC frequency conversion motor, centrifugal pump, weighing instrument with touch screen control box, filling machinery, cylinder filling gun, filter, pneumatic ball valve and so on. Among them, the control system is mainly composed of AT89S52 microcontroller, peripheral circuits, relays, potentiometers, weighing instruments and touch screen. Through the weighing module to calculate the amount of liquid, the sensor data into the control system control system and then control the motor operation, you can realize the real-time monitoring of the amount of liquid. The filling system mainly completes the collection of data from the weighing module, displaying the data by the touch screen, accepting the data input from the potentiometer, and controlling the stable operation of the control system by controlling the relays and solenoid valves, including the main program, the sensor data collection subroutine, the timer interrupt service program, and the LCD subroutine, etc. The controller enters into the program control, and then it will be controlled by the controller. After the controller enters the program control, it first detects the mode button to determine under which working mode the system is under. The set value of filling is collected by AD; then, the relay is opened. The motor operation collects the pulse number of the sensor and displays it on the LCD in real time. When the filling quantity corresponding to the number of pulses reaches the set value, close the relay to cut off the motor drive circuit. The contact switch of the solenoid valve of the filling gun in the quantitative filling control circuit remains normally closed, and the weighing module displays the current filling quantity.

The explosion-proof filling machine has both switching control and analog frequency control. Equipment can be automatic continuous operation, the movement of the point can be manually point operation, so that corresponds to a variety of operations of the input point, the need to display the state of the action of the information output point there are many. If these I/O signals are displayed by electrical buttons and indicators, it will greatly increase the number of hardware modules and electrical wiring, and the corresponding failure rate will also increase. We use a combination of PLC and touch screen program. Touch screen screen is designed with special configuration software, and then downloaded to the touch screen through the computer's RS-232C serial communication port. PLC and touch screen through the serial interface communication, connectivity is simple.

Filling equipment is designed with a total of 13 digital input points, including: 10 cylinder motion sensors, liquid level sensors 2, 1 photoelectric switch. 35 digital output points, including: 10 cylinder motion sensors, 2 liquid level sensors, 1 photoelectric switch. Digital output points 35, of which: 24 filling head solenoid valve control, cylinder movement solenoid valve control 10, liquid storage tank solenoid valve control 1. Weighing and filling machine frequency control system requires 1 analog input point and an analog output point. The speed measuring motor measures the rotational speed of the motor, the voltage signal is connected to the analog input point, after comparing with the given value and PID operation, the result of the operation is output from the analog output point, which is used as the control signal of the frequency converter to realize the frequency conversion speed control. The main control unit of the weighing and filling machine adopts PLC product CPU224, plus two digital expansion modules EM223 and one analog expansion module EM235, and the touch screen adopts Taiwan-made PWS3260. Frequency control system requires one analog input point and one analog output point. The speed measuring motor measures the rotational speed of the motor, the voltage value signal is connected to the analog input point, after comparing with the given value and PID operation, the result of the operation is output from the analog output point as the control signal of the frequency converter, so as to realize the frequency conversion speed regulation.

Filling system control program is prepared in the form of menu. Automatic functions include: run, pause, terminate, reset and so on. Manual functions include: all moving parts in, out, start, stop and so on. The alternating button function in ADP3 configuration software is utilized for programming. When the button is pressed and lifted, the corresponding intermediate relay of the PLC is set, so that the PLC can realize the in/out control of a moving part. Initial value setting: According to the user's needs, set the rotational speed, count value and other parameters, and monitor the upper limit of the parameters, once out of bounds, that is, to give a prompt. Operation monitoring: monitor the state of each device of the system, such as frequency converter, motor and other abnormal state, timely power-off protection, and give an alarm.

Multi-station liquid filling machine
The field management and control system of liquid filling machine based on single chip microcomputer, radio frequency card and network integration technology can control the filling of materials in real time and effectively. Realize the real-time detection of filling weight and the real-time opening and closing of solenoid valve in filling process, and upload data for effective microcomputer management.
Application of liquid pumping and mixing batching system
The batching system adopts dual CPU to form a redundant system, and the STEP7MicroWin V4.0SP6 programming software provided by Siemens is used as the man-machine interface to write debugging programs and download programs. The PC and PLC experimental machine are connected by a PC/PPI cable for communication, and the corresponding parameters are set.
Automatic liquid filling machine function application
Automatic liquid filling machine is controlled by frequency converter to realize stepless speed change, set the target weight, easy operation and fast filling speed, adopting large and small feeding and filling methods, optional computer connection or real-time printing of filling parameters such as filling date, serial number, net weight, tare weight, cumulative weight and so on.
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